Warehouse safety : a practical guide to preventing warehouse incidents and injuries

List of Figures .......................................................................................................... xi Foreword .................................................................................................................x. v Preface ...................................................................................................................x vii About the Author .................................................................................................... xxi Acknowlegements ................................................................................................. xxii ... Disclaimer ............................................................................................................ xxut 1 . Introduction to Warehouse Safety ........................................................................ 1 A National Concern for Safety in the Workplace .........................................................................1. . Warehouse Safety Study ..........................................................................................................3.. ... The Need for Warehouse Safety ................................................................................................5. .. Safety Needs for Warehouses ....................................................................................................5.. . OSHA Considerations .............................................................................................................8.. ... Summary ..................................................................................................................................... 9 References ...............................................................................................................................9.. .. 2 . Effective Warehouse Safety Programming .......................................................... 11 DuPont Corporation as a Leader .............................................................................................1.1.. Unsafe Conditions ................................................................................................................1..2.. .. Combination of Factors .........................................................................................................1..3. .. Safety Roles for Everyone ......................................................................................................1..3.. Management .....................................................................................................................1..4.. .. Workers ..............................................................................................................................1.4.. . Rating Supervisors' Performance in Safety ...............................................................................1.4. Use of the Rating Form .............................................................................................................1.5 Elements of SuccessfUl Safety Programs .................................................................................1.8.. . Delivering the Program to Employees .......................................................................................2..2 Management Responsibility ......................................................................................................2..3 Voluntary Protection Programs ..............................................................................................2..5. .. Benefits of VPP .................................................................................................................2.5.. .. OSHA's Awards for Excellence in Safety and Health .............................................................2..7 The Application Process ...................................................................................................2..7.. .. OSHA's Onsite Visit ..........................................................................................................3.2.. .. Site Document Review .......................................................................................................3.2.. . Summary ................................................................................................................................3..4. References ...............................................................................................................................3..4 iii iv 1 Warehouse Safetv 3 . New Employee Orientation ................................................................................. 35 Suggested Discussion and Tour Topics .....................................................................................3.6. Additional Program Elements .............................................................................................3..7.. . Warehouse Safety Rules ..........................................................................................................3..8. New Employee Orientation Checklist ....................................................................................4..0.. . Summary ...............................................................................................................................4..4.. References ...........................................................................................................................4..4.. ... 4 . Safe Materials Storage ........................................................................................ 45 Pallet Safety ............................................................................................................................... 45 Environmental Considerations for Pallets .................................................................................... 47 Racking ..............................................................................................................................4..7. ..... Additional information on racking .......................................................................................5..0.. Mezzanine Safety .................................................................................................................5..3. ... Summary ...........................................................................................................................5..4.. ..... References ...............................................................................................................................5.5.. 5. Fire Safety .......................................................................................................5 7 Fire Statistics .........................................................................................................................5.7.. .. Warehouse Fires ..................................................................................................................5..8.. ... Understanding Fire and Fire Extinguishers .................................................................................. 60 Fire Extinguishers ................................................................................................................... 61 Sprinkler Systems ....................................................................................................................... 67 Flammable and Combustible Liquids ......................................................................................7..1.. . Warehouse Storage ...............................................................................................................7..3.. .. Aerosols ..............................................................................................................................7.4.. Fire Considerations in High-Rack Storage ............................................................................7..4 Summary .................................................................................................................................7..5 Reference ............................................................................................................................7..7.. ... 6 . Safeguarding of Hazards .................................................................................... 79 Mezzanine Safety .....................................................................................................................8 0 Wheel chocks/ trailer restraints ..............................................................................................8..0.. . Guards for moving hazards ......................................................................................................... 82 Conveyors .............................................................................................................................. 83 Pulley Belts .........................................................................................................................8..4. Forklift Moving Parts ........................................................................................................8.4.. .. Safety Latches for Crane Hooks .............................................................................................8.5.. . Fixed Ladders ............................................................................................................................. 85 Trash Compactors ......................................................................................................................8 6 Skylights ................................................................................................................................8..7. Barriers for Guarding ...........................................................................................................8..8.. .. vi / Warehouse Safety Longitudinal Stability ............................................................................................................ 149 Features of Powered Industrial Trucks .................................................................................... 149 ANSI B56.1 Recommendations for Operator Training .............................................................. 150 Operator Qualifications ........................................................................................................ 150 Operator Training ................................................................................................................. 150 Operation of the powered industrial truck including: ................................................................. 152 Walkie Trucks ..........................................................................................................................1 53 While Operating a Walkie: .................................................................................................... 154 While Stacking Loads: ......................................................................................................1.5..5. While At the Dock: .........................................................................................................1..5..5. . Batteries: .............................................................................................................................. 156 Ramps and Inclines: .............................................................................................................. 156 Elevators: ............................................................................................................................ Additional Guidelines: ......................................................................................................... Fine-Tuning Operator Training ................................................................................................ OSHA Citations ...................................................................................................................... Attachments Require Training ............................................................................................. When Forklifts Make the Headlines ......................................................................................... Pedestrian Safety ..................................................................................................................... Additional Pedestrian Safeguards ......................................................................................... Operator Guidelines ............. : ............................................................................................... 166 OSHA's New Forklift Operator Training Standard .................................................................... 167 Summary ................................................................................................................................1. 67 References .........................................................................................................................1..6..7.. . 11. Materials Handling .......................................................................................... 169 Back Injuries and Back Support Belts ...................................................................................1..6..9 Back Injuries .......................................................................................................................1. 69 Back Belts ........................................................................................................................... 170 Conveyor Safety ....................................................................................................................... 175 Extendible Conveyors ........................................................................................................... 179 Conveyor Noise .................................................................................................................... 179 Cranes and Hoists .....................................................................................................................1 80 Operator Training ..............................................................................................................1..8. 0 Crane Safety Guidelines ......................................................................................................1..8 0 Hoists ...................................................................................................................................... 182 Summary ................................................................................................................................1. 83 References ..........................................................................................................................1..8..4.. 12. Warehouse Inspection Process: The Building and Industrial Trucks ............. 185 Powered Industrial Trucks ...................................................................................................1.8..5.. Pre-Use Inspections .............................................................................................................1. 86 Facility Inspections ................................................................................................................... 189 Table of Contents / vii Warehouse Items to Inspect ....................................................................................................1..9 3 Safety Audits ......................................................................................................................1..9..6. . Audit Content ...................................................................................................................1..9..8 Purposes of Auditing ............................................................................................................ 200 When Audits Are Conducted ................................................................................................2 00 Length of Audits .................................................................................................................. 201 Who Should Conduct the Audit? .....................................................................................2..0..1. Summary ............................................................................................................................2.0..1.. . References ...............................................................................................................................2. 03 13 . Ergonomics in the Warehouse ........................................................................ 205 Understanding Ergonomics and Its Costs .............................................................................2.0..5.. BLS Statistics ................................................................................................................2..0..6.. . Basics of Ergonomics ............................................................................................................2.0..7 Cumulative Trauma Disorders ..............................................................................................2..0..8 Ergonomic issues-hands and wrists ....................................................................................2..0..8 Carpal tunnel syndrome ...................................................................................................2..0..8. Tendinitis/tenosynovitis ..................................................................................................2..0..9.. DeQuervians disease ........................................................................................................2..0..9. Reynauds syndrome ............................................................................................................2..0 9 Ergonomic Issues-Arms and Shoulders .................................................................................. 209 Ergonomic Issues-the Back .................................................................................................... 210 Methods to Improve Ergonomics ........................................................................................... 213 Ergonomic Tips to Improve the Warehouse ..........................................................................2..1..5 Powered Industrial Trucks ................................................................................................2.1..5. Negative Ergonomic Factors ...........................................................................................2..1..6. Ergonomics in the Office .......................................................................................................... 217 Summary ................................................................................................................................. 218 References ...........................................................................................................................2..2..0. 14 . Chemical Exposures in the Workplace ............................................................ 221 The Hazard Communication Standard ..................................................................................2..2..1 Written program ....................................................................................................................... 222 Material Safety Data Sheets (MSDS) ........................................................................................ 222 Product Warning Labels ........................................................................................................... 224 Employee Training .............................................................................................................2..2..5. Flammable (Explosive) Limits ..............................................................................................2..2.6. Handling and Storage of Chemicals .....................................................................................2..2..6 Carbon Monoxide ...................................................................................................................2. 28 Evidence of CO exposure ......................................................................................................... 228 Measurements and Guidelines ..........................................................................................2..3..0. Summary ..............................................................................................................................2..3..1 viii / Warehouse Safetv References ...........................................................................................................................2.3..1.. 15 . Personal Protective Equipment ........................................................................ 233 Types of Equipment .............................................................................................................2..3..3. Hard hats ............................................................................................................................... 234 Foot Protection ........................................................................................................................ 236 Eye and Face Protection .........................................................................................................2..3 6 Safety Goggles ...................................................................................................................2..3..7.. Face Shields ....................................................................................................................2.4..0.. Cutting GogglesIWelding Helmets ..................................................................................2..4..1.. Gloves ..................................................................................................................................... 242 Respiratory Protection ...........................................................................................................2..4. 4 Written Program Requirements .........................................................................................2..4..5 New OSHA Rule ...........................................................................................................2..4..6.. . Respirator Selection .......................................................................................................2..4..6.. Dust Masks ........................................................................................................................2..4 7 New Filter Choices .........................................................................................................2..4..7.. Hearing Protection .............................................................................................................2..4..8.. Types of Equipment ...............................................................................................................2..4.9 Fall Arrest SystemsIFall Protection ......................................................................................2..5.2.. Rubber Aprons ......................................................................................................................... 254 Summary ................................................................................................................................. 254 References .......................................................................................................................2..5..5. .... 16 . Injuries, Incidents, and Investigations ............................................................ 257 The Nature, Causes, and Results of Injuries ...........................................................................2..5. 7 Work Interruption ............................................................................................................2..5..7. Contact ..............................................................................................................................2..5 8 Causes of Injuries ...................................................................................................................2..6 0 Unsafe Acts ........................................................................................................................2..6 1 Unsafe Conditions ...............................................................................................................2.6..3.. Injury Investigation .............................................................................................................2.6..7.. Incident Reporting ..................................................................................................................2.7. 2 Summary ................................................................................................................................. 273 References ............................................................................................................................... 275 17. Job Hazard Analysis ........................................................................................ 277 Definition of Job Hazard Analysis ..........................................................................................2.7..8 Basic Steps of a JHA ......................................................................................................2..7..8.. Defining the Word " Job .......................................................................................................... 278 Developing a JHA List ............................................................................................................. 279 Selecting the Job to be Analyzed .........................................................................................2..8..1. Starting the JHA Process ......................................................................................................2..8..2 Table of Contents / ix Selecting the Job ...................................................................................................................... 284 Forms Used for JHA ........................................................................................................2..8..4. .. Identifllng Potential Hazards or Injuries ................................................................................2..8.7 Completing the JHA ................................................................................................................. 288 Taking the Program Further .................................................................................................2..8..9. Economic Considerations for JHA .........................................................................................2..9. 0 Summary ................................................................................................................................. 291 References ...............................................................................................................................2. 92 18 . Warehouse Emergencies .................................................................................. 293 Written Program ......................................................................................................................2. 94 Summary ................................................................................................................................. 298 References ............................................................................................................................... 298 19 . Batteries and Fuels for Powered Equipment .................................................. 299 Electric Truck Batteries ............................................................................................................ 299 Changing the battery ............................................................................................................. 304 Liquified Petroleum Gas ........................................................................................................... 305 General Safety Guidelines ......................................................................................................... 305 Compressed Natural Gas (CNG) .............................................................................................. 307 Gasoline and Diesel Fuels .........................................................................................................3 09 Summary ...............................................................................................................................3..1 0 References ..............................................................................................................................3..1 1 20 . Miscellaneous .................................................................................................. 313 Ladder Safety ...........................................................................................................................3 13 Types of ladders ................................................................................................................... 313 Incentive and Recognition Programs ......................................................................................... 316 Confined Spaces ....................................................................................................................... 318 Confined Space Hazards .....................................................................................................3. 18 Types of Hazards in Confined Spaces ............................................................................... 319 Flammability Testing for Confined Spaces .........................................................................3..2..0 Employee Training .............................................................................................................3..2 1 Key Points to Consider ......................................................................................................... 322 Electrical Safety .....................................................................................................................3..2 2 Electrical Failures ...............................................................................................................3..2 3 Electrical Injuries .................................................................................................................. 323 Employee Training ............................................................................................................... 324 Welding and Cutting ............................................................................................................3..2..4. Toxic Gases and Fumes .......................................................................................................3. 24 General Safety Guidelines .....................................................................................................3 26 Torch-Cutting Operations .....................................................................................................3 27 Hot Work Permits ...............................................................................................................3..2 8 x / Warehouse Safetv Job Safety Observation .............................................................................................................3 30 JSO Benefits .......................................................................................................................3.3. 0 How JSO Works ...................................................................................................................3 31 Key Points of JSO ................................................................................................................3 33 Summary ................................................................................................................................. 334 References ...............................................................................................................................3. 34 Appendix A ............................................................................................................ 337 Appendix B ............................................................................................................ 341 Glossary ............................................................................